Diffusion plate used in direct-type backlight module and method for making the same

ABSTRACT

The present invention relates to a diffusion plate used in a direct-type backlight module and a method for making the same. At least one of the surfaces of the diffusion plate has a microstructure constituted by repeated undulation that can refract and diffuse the incident light beams that enter the diffusion plate. Therefore, the paths of the light beams after entering the diffusion plate are changed, which raises the luminance of the backlight module.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a diffusion plate used in a direct-typebacklight module and a method for making the same, particularly to adiffusion plate having a microstructure on the illuminated surfacethereof and a method for making the same.

2. Description of the Related Art

FIG. 1 shows a schematic view of a conventional direct-type backlightmodule. The direct-type backlight module 1 is used in a liquid crystaldisplay and comprises a diffusion plate 10, a plurality of lamps 12, areflector 14, a diffusion film 16, a brightness enhancement film (BEF)18 and a plurality of diffusion particles 19.

The diffusion plate 10 is a transparent body doped with the diffusionparticles 19 therein or thereon. The refractive index of the diffusionparticles 19 is different from that of the body of the diffusion plate10. The light beams in the diffusion plate 10 are diffused due to therefraction of the diffusion particles 19 so that the lamp mura betweenthe lamps 12 can be reduced. The diffusion plate 10 has a top surface101 and a bottom surface 102, wherein the bottom surface 102 is anilluminated surface for receiving the incident light beams emitted fromthe lamps 12 directly and the incident light beams reflected by thereflector 14. The top surface 101 of the diffusion plate 10 is attachedwith the diffusion film 16 and the brightness enhancement film 18. Thebrightness enhancement film 18 has a plurality of prisms thereon so asto concentrate the diffused light beams within the desired view angle ofthe liquid crystal display and raise the luminance in the desired viewangle of the backlight module 1.

The shortcoming of the diffusion plate 10 is that it only can diffusethe light beams. If the paths of the light beams need to be changed(e.g., concentrated after diffusion), this necessitates other opticalfilms (e.g., the diffusion film 16, and the brightness enhancement film18). However, the optical defects easily occur on the optical films dueto the environmental affect so that the yield of the backlight module 1is lowered. Additionally, the optical films are expensive, which raisesthe cost of the backlight module 1. Further, each optical film only hasa single optical function, which limits the optical design, and cannotbe adapted for various customized designs.

Consequently, there is an existing need for a novel and improveddiffusion plate and the method for making the same to solve theabove-mentioned problem.

SUMMARY OF THE INVENTION

One objective of the present invention is to provide a diffusion plateused in a direct-type backlight module. At least one of the surfaces ofthe diffusion plate has a microstructure constituted by repeatedundulation that can refract and diffuse the incident light beams thatenter the diffusion plate. Therefore, the paths of the light beams afterentering the diffusion plate are changed, which raises the luminance ofthe backlight module.

Another objective of the present invention is to provide a method formaking a diffusion plate used in a direct-type backlight module. Themethod utilizes a corolling process to make a diffusion plate withcomposite structure and form a microstructure on the surface of thediffusion plate. Therefore, the paths of the light beams after enteringthe diffusion plate are changed, which raises the luminance of thebacklight module.

Yet another objective of the present invention is to provide a methodfor making a diffusion plate used in a direct-type backlight module. Themethod utilizes rolling wheels to roll a material to form a diffusionplate with composite structure and form a microstructure on the surfaceof the diffusion plate. Therefore, the paths of the light beams afterentering the diffusion plate are changed, which raises the luminance ofthe backlight module.

Still another objective of the present invention is to provide adiffusion plate used in a direct-type backlight module. The diffusionplate itself has the functions of conventional optical films, which canreduce the variable factors of parts and raise the reliability of thebacklight module. Further, the cost of the backlight module is reduceddue to the omission of the expensive conventional optical films.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic view of a conventional direct-type backlightmodule;

FIG. 2 shows a schematic view of a direct-type backlight moduleaccording to a first embodiment of the present invention;

FIG. 3 shows a schematic view of a diffusion plate according to a secondembodiment of the present invention;

FIG. 4 shows a schematic view of a diffusion plate according to a thirdembodiment of the present invention;

FIG. 5 shows a schematic view of a diffusion plate according to a fourthembodiment of the present invention; and

FIG. 6 shows a flow diagram for making a diffusion plate used in adirect-type backlight module according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 2 shows a schematic view of a direct-type backlight moduleaccording to a first embodiment of the present invention. Thedirect-type backlight module 2 is used in a display device and comprisesa diffusion plate 20, a plurality of lamps 22, a reflector 24, and aplurality of diffusion particles 26.

The diffusion plate 20 is a transparent body doped with the diffusionparticles 26 therein. The second refractive index n₂ of the diffusionparticles 26 is different from the first refractive index n₁ of the bodyof the diffusion plate 20. The light beams in the diffusion plate 20 arediffused due to the refraction of the diffusion particles 26 so that thelamp mura between the lamps 22 can be reduced. The diffusion plate 20has a top surface 201 and a bottom surface 202.

The bottom surface 202 of the diffusion plate 20 is an illuminatedsurface for receiving the incident light beams emitted from the lamps 22directly and the incident light beams reflected by the reflector 24. Inthe embodiment, the diffusion plate 20 has a first microstructure 28 onthe bottom surface 202 thereof. The first microstructure 28 isconstituted by repeated undulation that can refract and diffuse theincident light beams that enter the diffusion plate 20. Therefore, thepaths of the light beams after entering the diffusion plate 20 arechanged, which raises the luminance of the backlight module 2. Theappearance of the first microstructure 28 includes but is not limited toplural parallel or cross grooves and extrusions. The shape of thegrooves or extrusions is selected from circular, rectangular,trapezoidal and triangular shapes.

The top surface 201 of the diffusion plate 20 is an output surface fortransmitting the light beams out of the diffusion plate 20. In theembodiment, the diffusion plate 20 has a second microstructure 29 on thetop surface 201 thereof. The second microstructure 29 is constituted byrepeated undulation that can concentrate the light beams diffused by thediffusion plate 20 and then transmit them. The appearance of the secondmicrostructure 29 includes but is not limited to plural parallel orcross grooves and extrusions. The shape of the grooves or extrusions iscircular, rectangular, trapezoidal, triangular or another shape.

FIG. 3 shows a schematic view of a diffusion plate according to a secondembodiment of the present invention. The diffusion plate 30 of theembodiment is used in a direct-type backlight module and comprises abody 31, an upper layer 32 and a plurality of diffusion particles 33.The body 31 has a top surface 311 and a bottom surface 312. The body 31has a first refractive index n₁. The diffusion particles 33 are doped inthe body 31 and have a second refractive index n₂. The light beams inthe body 31 are diffused due to the refraction of the diffusionparticles 33. The upper layer 32 is a transparent material and has a topsurface 321 and a bottom surface 322. The upper layer 32 has a fourthrefractive index n₄. In the embodiment, the first refractive index n₁ isdifferent from the second refractive index n₂, and the first refractiveindex n₁ is larger than the fourth refractive index n₄.

The bottom surface 312 of the body 31 is an illuminated surface forreceiving the incident light beams. In the embodiment, the body 31 has afirst microstructure 34 on the bottom surface 312 thereof. The firstmicrostructure 34 is constituted by repeated undulation that can refractand diffuse the incident light beams that enter the body 31. Therefore,the paths of the light beams after entering the diffusion plate 30 arechanged, which raises the luminance of the backlight module. Theappearance of the first microstructure 34 includes but is not limited toplural parallel or cross grooves and extrusions. The shape of thegrooves or extrusions is circular, rectangular, trapezoidal, triangularor another shape.

The bottom surface 322 of the upper layer 32 is disposed on the topsurface 311 of the body 31. The top surface 321 of the upper layer 32 isan output surface for transmitting the light beams out of the diffusionplate 30. In the embodiment, the upper layer 32 has a secondmicrostructure 35 on the top surface 321 thereof. The secondmicrostructure 35 is constituted by repeated undulation that canconcentrate the light beams diffused by the diffusion plate 30 and thentransmit them. The appearance of the second microstructure 35 includesbut is not limited to plural parallel or cross grooves and extrusions.The shape of the grooves or extrusions is circular, rectangular,trapezoidal, triangular or another shape.

FIG. 4 shows a schematic view of a diffusion plate according to a thirdembodiment of the present invention. The diffusion plate 40 of theembodiment comprises a body 41, a lower layer 42 and a plurality ofdiffusion particles 43. The body 41 has a top surface 411 and a bottomsurface 412. The body 41 has a first refractive index n₁. The diffusionparticles 43 are doped in the body 41 and have a second refractive indexn₂. The light beams in the body 41 are diffused due to the refraction ofthe diffusion particles 43. The lower layer 42 is a transparent materialand has a top surface 421 and a bottom surface 422. The lower layer 42has a third refractive index n₃. In the embodiment, the first refractiveindex n₁ is different from the second refractive index n₂, and the firstrefractive index n₁ is larger than the third refractive index n₃.

The top surface 421 of the lower layer 42 is attached to the bottomsurface 412 of the body 41. The bottom surface 422 of the lower layer 42is an illuminated surface for receiving the incident light beams. In theembodiment, the lower layer 42 has a first microstructure 44 on thebottom surface 422 thereof. The first microstructure 44 is constitutedby repeated undulation that can refract and diffuse the incident lightbeams that enter the diffusion plate 40. Therefore, the paths of thelight beams after entering the diffusion plate 40 are changed, whichraises the luminance of the backlight module. The appearance of thefirst microstructure 44 includes but is not limited to plural parallelor cross grooves and extrusions. The shape of the grooves or extrusionsis circular, rectangular, trapezoidal, triangular or another shape.

The top surface 411 of the body 41 is an output surface for transmittingthe light beams out of the diffusion plate 40. In the embodiment, thebody 41 has a second microstructure 45 on the top surface 411 thereof.The second microstructure 45 is constituted by repeated undulation thatcan concentrate the light beams diffused by the diffusion plate 40 andthen transmit them. The appearance of the second microstructure 45includes but is not limited to plural parallel or cross grooves andextrusions. The shape of the grooves or extrusions is circular,rectangular, trapezoidal, triangular or another shape.

FIG. 5 shows a schematic view of a diffusion plate according to a fourthembodiment of the present invention. The diffusion plate 50 of theembodiment comprises a body 51, a lower layer 52, a plurality ofdiffusion particles 53 and an upper layer 54. The body 51 has a topsurface 511 and a bottom surface 512. The body 51 has a first refractiveindex n₁. The diffusion particles 53 are doped in the body 51 and have asecond refractive index n₂. The light beams in the body 51 are diffuseddue to the refraction of the diffusion particles 53. The lower layer 52is a transparent material and has a top surface 521 and a bottom surface522. The lower layer 52 has a third refractive index n₃. The upper layer54 is a transparent material and has a top surface 541 and a bottomsurface 542. The upper layer 54 has a fourth refractive index n₄. In theembodiment, the first refractive index n₁ is different from the secondrefractive index n₂, the first refractive index n₁ is larger than thethird refractive index n₃, and the first refractive index n₁ is largerthan the fourth refractive index n₄.

The top surface 521 of the lower layer 52 is attached to the bottomsurface 512 of the body 51. The bottom surface 522 of the lower layer 52is an illuminated surface for receiving the incident light beams. In theembodiment, the lower layer 52 has a first microstructure 55 on thebottom surface 522 thereof. The first microstructure 55 is constitutedby repeated undulation that can refract and diffuse the incident lightbeams that enter the diffusion plate 50. Therefore, the paths of thelight beams after entering the diffusion plate 50 are changed, whichraises the luminance of the backlight module. The appearance of thefirst microstructure 55 includes but is not limited to plural parallelor cross grooves and extrusions. The shape of the grooves or extrusionsis circular, rectangular, trapezoidal, triangular or another shape.

The bottom surface 542 of the upper layer 54 is attached to the topsurface 511 of the body 51. The top surface 541 of the upper layer 54 isan output surface for transmitting the light beams out of the diffusionplate 50. In the embodiment, the upper layer 54 has a secondmicrostructure 56 on the top surface 541 thereof. The secondmicrostructure 56 is constituted by repeated undulation that canconcentrate the light beams diffused by the diffusion plate 50 and thentransmit them. The appearance of the second microstructure 56 includesbut is not limited to plural parallel or cross grooves and extrusions.The shape of the grooves or extrusions is circular, rectangular,trapezoidal, triangular or another shape.

FIG. 6 shows a flow diagram for making a diffusion plate used in adirect-type backlight module according to the present invention. First,step S61 is to provide a material. Then, step S62 is to provide at leasttwo rolling wheels, wherein at least one of the rolling wheels hasrepeated undulation on the surface thereof. Finally, step S63 is toutilize the rolling wheels to roll the material to form a diffusionplate, wherein the diffusion plate has a top surface and a bottomsurface, and at least one of the surfaces has a first microstructureconstituted by the repeated undulation corresponding to the rollingwheel. Therefore, the paths of the light beams after entering thediffusion plate are changed, which raises the luminance of the backlightmodule that comprises the diffusion plate.

Take a method for making the diffusion plate 20 of the first embodimentin FIG. 2 for example. The material in step S61 is a body material.Then, step S62 is to provide an upper rolling wheel and a lower wheel,wherein the upper rolling wheel has a plurality of triangular extrusionscorresponding to the second microstructure 29 on the surface thereof soas to form the prism structure of the second microstructure 29, and thelower rolling wheel has a plurality of circular extrusions correspondingto the first microstructure 28 on the surface thereof so as to form thecircular grooves of the first microstructure 28. Finally, step S63 is toutilize the upper rolling wheel and the lower wheel to roll the bodymaterial to form the diffusion plate 20.

Take a method for making the diffusion plate 30 of the second embodimentin FIG. 3 for example. The material in step S61 comprises a bodymaterial and an upper layer material, wherein the body material has afirst refractive index n₁, the upper layer material has a fourthrefractive index n₄, and the first refractive index n₁ is larger thanthe fourth refractive index n₄. Preferably, the upper layer material isa transparent curable or thermal curable resin. Then, step S62 is toprovide an upper rolling wheel and a lower wheel, wherein the upperrolling wheel has a plurality of triangular extrusions corresponding tothe second microstructure 35 on the surface thereof so as to form theprism structure of the second microstructure 35, and the lower rollingwheel has a plurality of circular extrusions corresponding to the firstmicrostructure 34 on the surface thereof so as to form the circulargrooves of the first microstructure 34. Then, in step S63, the bodymaterial is disposed under the upper layer material, or the upper layermaterial is coated on the top surface of the body material. Thediffusion plate 30 is formed by a corolling process utilizing the upperrolling wheel and the lower wheel. Finally, the diffusion plate 30 iscured by heat or UV light, wherein the body material forms the body 31,and the upper layer material forms the upper layer 32.

Take a method for making the diffusion plate 40 of the third embodimentin FIG. 4 for example. The material in step S61 comprises a bodymaterial and a lower layer material, wherein the body material has afirst refractive index n₁, the lower layer material has a thirdrefractive index n₃, and the first refractive index n₁ is larger thanthe third refractive index n₃. Preferably, the lower layer material is atransparent curable or thermal curable resin. Then, step S62 is toprovide an upper rolling wheel and a lower wheel, wherein the upperrolling wheel has a plurality of triangular extrusions corresponding tothe second microstructure 45 on the surface thereof so as to form theprism structure of the second microstructure 45, and the lower rollingwheel has a plurality of circular extrusions corresponding to the firstmicrostructure 44 on the surface thereof so as to form the circulargrooves of the first microstructure 44. Then, in step S63, the bodymaterial is disposed over the lower layer material, or the lower layermaterial is coated on the bottom surface of the body material. Thediffusion plate 40 is formed by a corolling process utilizing the upperrolling wheel and the lower wheel. Finally, the diffusion plate 40 iscured by heat or UV light, wherein the body material forms the body 41,and the lower layer material forms the lower layer 42.

Take a method for making the diffusion plate 50 of the fourth embodimentin FIG. 5 for example. The material in step S61 comprises a bodymaterial, an upper material and a lower layer material, wherein the bodymaterial has a first refractive index n₁, the upper layer material has afourth refractive index n₄, the lower layer material has a thirdrefractive index n₃, and the first refractive index n₁ is larger thanthe third refractive index n₃ and the fourth refractive index n₄.Preferably, the lower layer material and upper layer material aretransparent curable or thermal curable resin. Then, step S62 is toprovide an upper rolling wheel and a lower wheel, wherein the upperrolling wheel has a plurality of triangular extrusions corresponding tothe second microstructure 56 on the surface thereof so as to form theprism structure of the second microstructure 56, and the lower rollingwheel has a plurality of circular extrusions corresponding to the firstmicrostructure 55 on the surface thereof so as to form the circulargrooves of the first microstructure 55. Then, in step S63, the bodymaterial is disposed over the lower layer material, and the upper layermaterial is disposed over the body material, or the lower layer materialis coated on the bottom surface of the body material and the upper layermaterial is coated on the top surface of the body material. Thediffusion plate 50 is formed by a corolling process utilizing the upperrolling wheel and the lower wheel. Finally, the diffusion plate 50 iscured by heat or UV light, wherein the body material forms the body 51,the upper layer material forms the upper layer 54, and the lower layermaterial forms the lower layer 52.

While several embodiments of the present invention have been illustratedand described, various modifications and improvements can be made bythose skilled in the art. The embodiments of the present invention aretherefore described in an illustrative but not restrictive sense. It isintended that the present invention may not be limited to the particularforms as illustrated, and that all modifications which maintain thespirit and scope of the present invention are within the scope asdefined in the appended claims.

1-23. (canceled)
 24. A method for making a diffusion plate used in adirect-type backlight module, comprising the steps of: (a) providing aplastic material; (b) providing at least two rolling wheels, wherein atleast one of the rolling wheels has repeated undulation on the surfacethereof; and (c) utilizing the rolling wheels to roll the material toform a diffusion plate, wherein the diffusion plate has a top surfaceand a bottom surface, and at least one of the surfaces has a firstmicrostructure constituted by the repeated undulation corresponding tothe rolling wheel.
 25. The method according to claim 24, wherein therepeated undulation in step (b) is constituted by a plurality ofparallel or cross extrusions.
 26. The method according to claim 25,wherein the shape of the extrusions is circular.
 27. The methodaccording to claim 25, wherein the shape of the extrusions isrectangular.
 28. The method according to claim 24, wherein step (b) isto provide an upper rolling wheel and a lower wheel, wherein both wheelshave repeated undulation on the surface thereof
 29. The method accordingto claim 24, wherein the material in step (a) comprises a body materialand a lower layer material, the body material has a first refractiveindex, the lower layer material has a third refractive index, the firstrefractive index is larger than the third refractive index, the bodymaterial is disposed over the lower layer material in step (c), and thediffusion plate is formed by corolling.
 30. The method according toclaim 24, wherein the material in step (a) comprises a body material andan upper layer material, the body material has a first refractive index,the upper layer material has a fourth refractive index, the firstrefractive index is larger than the fourth refractive index, the bodymaterial is disposed under the upper layer material in step (c), and thediffusion plate is formed by corolling.
 31. The method according toclaim 24, wherein the material in step (a) comprises a body material, anupper layer material and a lower layer material, the body material has afirst refractive index, the upper layer material has a fourth refractiveindex, the lower layer material has a third refractive index, the firstrefractive index is larger than the third and fourth refractive index,the body material is disposed between the lower layer material and theupper layer material in step (c), and the diffusion plate is formed bycorolling.
 32. The method according to claim 24, further comprising astep of curing the diffusion plate.